Apparatus for melting titanium to form ingots



June 2, 1953 s. A. HERRES 2,640,860

APPARATUS FOR MELTING TITANIUM TO FORM INGQTS Filed Oct. 21, 1949 6Sheets-Sheet l Schuyler AHerres BY 3% 6% FOR Green, McCa/hlsferGMi/IerH/S ATTORNEYS June 2, 1953 s. A. HERRES APPARATUS FOR MELTING TITANIUMTO FORM INGOTS 6 Sheets-Sheet 2 Filed Oct. 21, 1949 11 iss & F195 m o bc l l u a 9 n m 0 ra n 5 w m w u 4 u w 2 a u 0 I: a 3 O I w b I: 4 5 5 46 O. o 4 -m 1 5 5/ 9- 2 2 2 w m u u M m n .8 r m. u N A m I r M h pg 0W. e M. u. 5 m 8 Hi m 3 Y 6 2 B R b 0 7 F I o 6 4 /////////////A/ I c mM g H mg AT romvz rs 6 Sheets-Sheet s S. A. HERRES mil APPARATUS FORMELTING TITANIUM To FORM INGOTS 1 llll June 2, 1953 Filed Oct. 21, 1949IN VEN TOR.

' Schuyler A. Hones BY 7 mm, FOR Grun, McCaI/Isfer 8 Miller HISATTORNEYS June 2, 1953 s. A. 'H'ERRES 2,640,860

APPARATUS FOR MELTING TITANIUM To FORM INGOTS Filed Oct. 21, 1949 6Sheets-Sheet 4 i ,INVENOR.

\ Schuyler A. Harms 1 FOR Group, Mace/liver 8 Miller HIS AT T DRIVE Y5June 2, 1953 s. A. HERRES 2,640,860

APPARATUS MELTING TITANIUM TO FORM INGOTS Filed Oct- 21, 1949 sShets-Sheet 5 lOOb INVENTOR. Schuyler A. Herres "m mm FOR Green,McCaI/isfer 8 Miller H/S ATTORNEYS June 2, 1953 s. A. HERRES APPARATUSFOR MELTING TITANIUM TO FORM INGOTS Filed Oct. 21, 1949 6 Sheets-Sheet 6FOR Green, McCal/ister 8 Miller HIS ATTORNEYS Patented June 2, 1953APPARATUS FOR MELTING: TITANIUM T FOR-M INGOTS Schuyler A. Herres,Albany, N. Y., assignor to Allegheny Ludlum Steel Corporation,Brackenridge, Pa., a, corporation of Pennsylvania Application October21, 1949, Serial No. 122,717

8 claims. 1

This invention pertains to iinnrovcrl proce dure and apparatus formelting titaniu n metal and titanium base metal. One phase of myinvention pertains particularly to the employment of, a consumableelectrode of titanium metal or titanium base alloy metal in an arcfurnace or crucible.

In accordance with my invention, a consuma able electrode is made bypro-forming titanium powder or titanium spon e metal up to one inch inparticle size at a pressure of approximately 1.5 tons per sq. in. toform sticks of convenient length and cross section. The pressing is prefcmbly carried out at room temperature and addi tions of other metals orcompounds he in cornorated in the stick, to rovide alloy ingots of anydesired composition. That is, the desired percentages of metal elementssuch as iron, chromium, molybdenum, tungsten, manganese, nickel andother alloying elements may be initial- 1y proportioned to, the titaniumpowder or sponge metal and ground to suitable particle sizes up to oneinch, mixed with the titanium powder or sponge metal, and. thenpress-formed with the latter into the sticks. If gaseous elements suchas oxygen and nitrogen are to be employed as alloying elements,relatively small proportions of oxides or nitrides of the alloyin metalsmay be employed instead of the pure metals, provided that the electricalconductivity of the sticks is not appreciably affected. For thispurpose, the core may he titanium metal With the metallic compounds as asurface layer thereabout.

The prc-formed sticks are continuously and progressively fed endwise aselectrodes into on arc-melting furnace or crucible at a rate dependingupon the rate of melting, to thereby build up an ingot. The rate of feedis preferably adjusted. to provide an arc voltageof about 30 volts; therate of melting is regulated within Wide limits by the are amperage.Either A. C. or D. C. may be used for the arc current. Although I havejoined the preformed s hs together by mechanical fcstenings, l1 lire tosecure them by an auxiliary flash welding circuit they are being fedtowards or into the furnace; threaded sticks, electric resistancewelding, etc. also be employed.

Also, in accordance with my invention, nddh tional titanium metal,alloying clcments (metals and may be introduced directly into thefurnace the electrode melting operation and the metal elements meltedalong with a, con sumahlc titanium electrode or a plurality ofelectrodes, ii usod. An ambient atmosphere is :raintcincd about thtitanium basc sticks, as "at-ell as witl'lin the furnace and about adelivery end thereof that is non-contaminatin 0f t titanium. Gases whichare inert to titanium,

such as argon, helium and neon. 01, a, vacuum nay be employed for thispurpose.

When the ingot has. been built up, t0 a, sumcient depth or length, thearcing current may be turned off, the, electrode iced stonped, the cot.-tom of the furnace removed, the solidified ingot, dropped, and thecomplete ingot, removed or a major portion thereof severed from a,portion retained in the furnace 0.17 a ain nitiating 3 melting arc. Iprovide meansv for sawing on: the ingot within an airlock chamber andfor pcriodically delivering the, sawedwfi ingot, imrough an airlock whenit has cooled Sufiiciently to he non-reactive with atmospheric ases.

In the structural, arrangements, for illustrating the principles of myinvention, Figure 1 is a top plan View of a melting and ed a aratusconstru ted in a corda ce wi h my invent on;

Fi ur 2 is a sid sectional v w in devotion taken along the line III-11of Figure 1 and also showing additional appa atus for suppl ing; W ldingcurr nt, arc current, and fo removing ingots that have been formed;

Figure 3 is a side sectiqnal View in elevation taken along the line.Illsill of Figure 1 and also showin fluid mean or actuat n sti kfeodingmechanism;

Figure 4 is a, s ti a detail f a port on the. feedin m chanism o Figureshowing t n an inoperative or raised position as mparcd to the operativeor lowered position of figure 3;

F g 5 is a h r o ta sectional view taken along the line V--V of Figure3;

' mechanism, as provided by a pair of dr ven rolls;

Figure 7A s a z n al se tion View t ken alon he. line 'VXIA VIIA. fFigure 2;

Figure 8 is a horizontal se tion taken a ng the li V I -Vl .I o 2 an ilus rat s a pair of; idler rollers for guiding the sticks;

Fi ure. 9 is a ction s mil r to th t o Figure '1. but illustrat s.modified typ of fcedn mechanism for r u d s icks;

Figures 10 and il are vertical sectional views somewhat diagrammaticallyillustrating a mothod of forming the Sticks;

Fi ure 12 is a v rtical ctional detail le vstion t u h a o r p rtion ofhe s ructure of Figure l, taken a o he l ne X I- 3 1 I Fi m 13 an shwing a lowered position o o hot= tom wall of the furnocfi as effected bya swing arm, prior to removing an ingot; in Figure 3, the iumc e bottomwall. is s 1 nv a d co ition incident to an arwm li ns cp i on; '1

Fi ure is a hor nta sect on l iew tak n through a top portion of anenclosure for the bottom of the furnace of Figure 2 and illustrating theoperation of the furnace bottom wall swing arm of Figure 12 and of aswingablc arm carrying an ingot-cutting saw mechanism;

Figure 14 is a vertical sectional view in elevation taken along the lineXIVXIV of Figure 13;

Figure 15 is a vertical sectional View showing details of the structureemployed within the enclosure for the bottom of the furnace and takenalong the line XVXV of Figure 13:

Figure 16 is a horizontal sectional view taken along the line XVIXVI ofFigure 15 and showing ingot delivery structure; and,

Figure 17 is a somewhat diagrammatic view in elevation illustrating acircuit that may be employed for simultaneously operating threeconsumable electrodes in separate furnaces or in a common furnace; thisview illustrates how threephase A. C. current may be employed forsupplying current to a plurality of electrodes.

Referring particularly to Figure 2 of the draw ings, I have shown acrucible or furnace I provided with a jacketed cooling chamber A anddefined by inner walls Ila, outer walls llb, a top wall l2a and a bottomwall lzb. Cooling fluid, such as water, may be circulated through thechamber A by means of an inlet Ho and an outlet lld. The inner wall llais preferably of copper, while the outer wall llb may be of steel or asuitable alloy.

A top cover plate member l4 is securely mounted on the top wall I20, bymeans of bolt and nut assemblies l5. The cover plate member I4 isinsulated from the top wall l2a by an insulating and fluid-sealing-ofigasket l3 located therebetween and by insulating sleeves l3a about thebolt and nut assemblies l5.

A central melting chamber is defined by the inner or lining walls llaand may be evacuated of contaminating gases through a passageway Mu, inthe cover member l4 and an outlet Mb. Ii, as also contemplated, themelting chamber is to be supplied with a non-contaminating gaseousatmosphere of asuitable gas such as argon, helium, or neon, a pair ofpassageways Ma and connections Mb may be provided, one for introducingthe non-contaminating gas and the other for exhausting partiallycontaminated gas.

The top cover member E4 is also shown provided with an enclosure I!about a center feed opening l6 therethrough that carries gasket materialIE to prevent the introduction of ethics pheric gases into the iurance lI! to, if desired,

seal off the furnace chamber from a superimposed feed enclosure 2020'.An outwardly and upwardly sloped feed pipe I9 is shown extendin throughthe top or cover plate member l4. and is provided with a threaded caplac and a gasket l9b for closing it off from the atmosphere. The pipe l9may be used to introduce alloying metals or elements, or such elementswith a noncontaminating gas.

Above the top of the melting furnace or crucible I0, I have shown thetwo-part feed chamber enclosure 20-2ll which may be evacuated through aconnection 20a or may be provided with a flow of non-contaminating gasby a pair of such connections. The bottom part 20 of the enclosure maybe secured as by welding to the top plate member Hi. The upper part 29of the enclosure has a top closure wall 3i provided with a central feedopening therethrough; the latter is defined by a rectangular feed orguide flange 32 (if the sticks are oi rectangular cross-secticn or by acircular or annular fee" and guide flange 32 (if the sticks are ofrounded section, Figure 9). The flange 32 extends vertically into thefeed chamber. It will be noted that the flange 32 at its top has aconeshaped opening to permit easy introduction of a sticiz, such as B"and terminates in a port 1. of uniform and lesser diameter (slightclearance is provided with the stick) which holds the sticlz in avertically aligned relationship as it fed therealong. Upper and lowerroll pairs 2 la- SSE 2.) and 2 l a2l'l; are located in a verticallyspacedapart relationship within the chamber def led by the enclosure2i!2il to rec-ive sticks and guide them into the crucible The upper set.as shown in Figures 3 and 6, are idler rolls and the lower set, as shownin Figures 3 and '7, positive feed rolls.

The upper part 20 of the enclosure has a bot tom rim flange Zilb and thelower part 2E has a top rim flange Zllb that abut on an electricalinsulating and fluid sealing gasket 200 that is interposed therebetween.Insulating sleeves 2001 extend through the flanges 29b, 2H), and thegasket Zllc and are adapted to receive nut and bolt assemblies Zlle forsecuring the rim flanges together.

Referring particularly to Figures 3 and 'Z, the illustrated lower pairof rolls El'a and 2lb have spaced-apart flanges 22 for guiding a stickof square or rectangular cross-section and shafts that are journaled attheir opposite ends by bearings 23' and 24. The bearings 23' and 2:1 aremounted on cross pieces or members 33' that are secured at their ends tothe enclosure part 20. Insulating material 33's is interposed betweenthe bearings and the pieces 33 to, like the motor gear 26, preventcurrent supplied line 12a from being shorted. The feed rcll Zlu. has aspur gear 25a splined or secured thereon; the feed roll 2lb has asimilar spur gear 2% secured or splined thereon. It will be noted thatthe spur gears 25a and 252) mesh with each other and are driven by motorgear 28 (of Micarta or other suitable non-conducting or electricalinsulating material) wh ch meshes with one of the spur gears 25b and isisfi'v'fld on a shaft 27 of a speed reduction unit 28. The unit 28 isactuated through a coupling or connection 29 by the drive shaft of amotor 30. It will thus be seen that the rolls 2la and 2lb may bepositively driven at relatively slow speed to continuously feed aconsumable electrode to the furnace It. In Figure 9, I have shown aslightly modified construction wherein the feed rolls 2Ic and 2l'd areof concave shape to feed a circular stick or electrode Br.

As shown in Figure 8, the upper pair of rolls (idler) 2la and Zlb are ofsimilar design and mounting to the lower or feed rolls 2 l 'a and 2 l'7), except that they are not provided with means for positively drivingthem. Their bearings 23 and 24 are mounted in a similar manner by meansof insulating material 33a and cross pieces 33 on the upper enclosurepart 20. The rolls Zla and 2lb are connected through bearings 23 toelectrical line Ila.

In figures 10 and 11 I have somewhat diagrammatically shown a press 5having a removable bottom 8 and a plunger 1 for compacting sponge orpowdered titanium 8, etc. into a stick B In Figures 1, 2 and 3 to 6,inclusive, I have shown a carrier wheel or magazine 38 provided withradially-extending spaced-apart compartments 38a for carrying individualelectrode sticks, and means for feeding the sticks from a com partmentthat is in alignment with. the feed flange 32 of the enclosure part Thecompartments 384; preferably have a shape corresponding to the shape ofthe sticlzs to be carried therein. In accordance with my invention, theelectrode sticks which may be of any suitable cross section, but arepreferably rectangular, are pressformed (see Figures 1.0 and 11),delivered to the compartments sea of the carrier 38 (see Figure 5)through an airlock delivery chute 55 (see Figure 3), and are thenintermittently pushed through the feed flange 32.

I have provided an enclosure 35 that is superimposed on the feedenclosure part Eli and that encloses the carrier wheel 33 which isadapted to be rotated intermittently. The carrier wheel 38 is splineclor secured on a central, vertical shaft 39 which at its lower end isjeurnaled within bearings Ma mounted. in an offset or depressed portion31a of the top wall 3! of the feed enclosure part 20. At its other theshaft 39 is journalecl within a bearing :1?) which is carried by abearing box Ml mounted on a top wall 3'! of the enclosure It will benoted that the cylindrical side wall or shell of the enclosure 35extends in a spaced-apart relationship about the rotatable carrier feedwheel or casting 38 and is secured. on the top well ill of the feedenclosure part Zll by colt nut assemblies 34.

As shown particularly in Figures 1,. 2 and sprocket wheel 41. is keyedon a top end of the shaft 39 and is driven a chain t3 and a sprocketwheel M. The sprocket wheel 4% is splinecl 01: secured to a drive shaft5 5 of an actuating motor 46. The motor #55 is provided with a slipcoupling Mia between two parts of its shaft 45, so that the wheel 3%!will rotate until of the sticks in one of its compartments 38c alignswith the feed. and falls or is through a feed hole in the bottom of theenclosure 535 to stop the rotation. of the wheel. At such time, thecoupling 35.; slips and. permits the motor Gfi to continue to rotate.Such stick is then forcefed. downwardly between the upper pair of feedrolls 2M. and. 2th by a piston pusher head. 49b. The rotation of thewheel is not resumed until the stick has 1 fully fed out of itscompartment 38aand the piston pusher head 4912 has been drawn upwardlyout of the compartment into offset portion Ella of the top wall. 31. Atthis time. the wh el 38 is, again slowly rotated. to position ne tcompartment 33a in an enrlwise aligned feeding position with the feedflange 32, and the oneration continued.

shown in Pictures 3. 5 and 6. plate member 80 is operably positionedDGJWESFJ' slotted to face 3!?) of the wall ill of enclosure part 26 anda bottom edge of the side wall 35 of the enclosure The member so is thusadapted to slide along th it (ill; in Wall 3! to cover its feed openinit is used toprevent any sticks from drop enclwise into the feed flange32 when the compartments of the carrier wheel 33 are beingpreliminarilyfilled with sticks. A E2 secured to the wall 365 to extend fully aroundthe slot 3th and depres- ,t file in t o f e of the wall (it et material.sealing oil the joint provided with the member 6%. As shown in Figures 5and 6, the shoe member has an operating handle. 6!. An offset abutmentportion 6M cooperates with a pin 31d that ex- 6. tends upwardly from thewall it to limit the maximum outward movement of the slide member Thewheel of Figure 5 will receive eight sticks;

1 the selected number of compartments 38a will depend: on the desiredsize of ingot to he built up in the furnace Ill. That is, I contemplaterefilling the carrierwheel 38 while a iormed ingot is being dropped andsevered at the bottom of the furnace.

Referring particularly to Figures" 2., 3, 4, 5 and 6, a piston cylinderor chamber wall 5c of a fluid motor is secured a by bolts 48 to the topwall 31 of the enclosure 35? and carries a piston head Ma that ismountedon an upper end of a, piston rod The pusher head 49b is mounted on thelower end of the rod 4%. It Will benoted that the piston head Maadapted: to slide up and down within the chamber defined by the cylinderwall an and that the pusher head 49b is adapted to slide no and clownwithin a periodically aligned compartment 3630:. The head 49?; isadapted to be withdrawn or out of the. compartment- 38a into the ofisetportion 37a in the top Wall 3'! of the enclosure 35;. A top wall 5! issecured over the cylinder 5% and carries a pressure relief and safetyvalve 5211.; a second. valve 521) of the same type is mounted: in thelower end of the cylinder 56.

The cylinder to provided with a passageway Ella into itsunper end and apassageway 5!?) into its lower end for supplying hydraulic or anysuitablepressure to opposite ends of the piston its to moveit up anddown within the chamber: 01!? the cylinder. The passageway 5m conheated:to line 53 and the passageway 5!?) is connected to line 54. Adual-acting control valve fili lgnctuated to shut oil flow throughboththe lines 53 and 55 when the piston 49a is in its upper position andthe slide plate 63 has moved to its inner position. When the slide plateSi is moved to its outer position, it presses an op erating arm 56 ofthe valve 55 to an open po sition against the tension of its spring,thus permitting fluid. to flow along both of the lines 53 and 54.Packing Ella is positioned within the lower of the cylinder 58 and aboutthe rod is to seal oh? the piston chamber.

A- doubleacting line-reversing valve 5? is positionecl in the fluid.lines 53 li tbeyond the valve 55. 'Ih-e valve 5? is actuated by an arm58 to either cause a positive flow through line 53 by connecting it tosupply line lite and, a return now through line fill by connecting it toreturn line 51m. or to cause a positive flow through line 54 byconnecting it to supply line 53a and a re turn. flow throush line 53 byconnecting it to the By reversing the valve 51', the

or his to push. on enclwise-alignecl stick out tluoue the feed flange32, withdraw the pusher see, p. it the carrier 33 to rotate one step andpresent the next successive stick, and then push it endwise through feedflange 32 and he tween the upper pair of guide rolls 2 la 2th.

The carrier 38 is slowly rotatedv while the sticks are fed into thecompartments we, through a chute (see Figure The chute 55 extendsupwardly from the top wall 3-! of the enclosure 35 and; is normallyclosed by cover lid that is hinged at 51' and locked in position by athumbnut and. pivot pin assembly at. The 69 is pivoted at W to the chuteand is adapted to extend into an open-end slot 66s of the lid M. Agasket 68 seals off the cover 66 when it is in its closed position.During the filling of the compartments 38a, the pusher 49b is raised toits extreme upper position to clear the carrier 38, the closure plate 60is moved inwardly to close up the opening in the bottom of the chamberof the enclosure 35, the valve 55 is shut off, and the carrier 38 isrotated by the motor 46 to progressively present each of the compartmentopenings 38a to the feed chute.

Referring to Figure 2 of the drawings, the bottom of the furnace I isclosed off by a bottom plate or wall IE that is carried by a swing armmember I and is secured as by brazing within the wall portions of anopening I50. therethrough. The opening a corresponds in diameter to theinner diameter of the wall Ila of the furnace II) that is closed off atits top by the bottom. plate 75 (preferably of copper). A plate ll(preferably of ferrous metal) is secured as by welding on a bottom faceof the member I5 to close oil the bottom of the opening 75a and to, withthe plate 16, define a cooling chamber I) through which cooling fluidsuch as water is circulated by inlet and outlet connections Ila and 11b.

In Figure 2 I have indicated starting metal in the furnace i0 by C, asmall portion of which may be inserted therein to start the operationand which will then build up as the electrode sticks B, B, B", etc. aremelted down. After an ingot I of suitable size has been built up, thearm member I5 may be lowered and swung out of position and the ingotremoved or cut off, as shown in Figures 14 and 15, Within a bottom,sealed-off enclosure 90. lhe enclosure 90 has a connection 00a that maybe employed to apply a vacuum, or may have a pair of such connectionsfor supplying and exhausting an inert gas.

The construction of the swingable arm member 75 which carries the bottomwall I6 of the crucible or furnace, is shown particularly in Figures 2,12

and 13. It will be noted that it is positioned vertically by a pair offluid-actuated motors 88 that are secured to extend upwardly from floorstands BI and are actuated by inlet and outlet connections 88a and 88bto raise and lower their pistons 89 and to thus raise and lower themember I5 on a vertical pivot pin I9. A threaded-on nut 19a serves as astop to limit the maximum extent of the upward movement of arm member 15on the pin I9. A bearing sleeve 80a extends through the arm member 75and about the pin 79.

A swing pin 5?. extends upwardly through a bearing sleeve 8% in an endof the arm I5 and is reduced and threaded at its lower end for mountingon a piston rod 83 of a fluid-actuated motor 84. A nut 82a secures areduced and threaded end of the pin 8?. on the rod 83. It will be notedthat the arm member I5 is free to move vertically up and down on thepins 19 and 82 when the fluid motors 88 are operated. In this manner,the bottom wall 18 of the furnace can be raised and lowered out ofposition with respect to the inner wall I Ia thereof. The motor 84 whichoperates to swing the arm I5 is actuated by fluid connections 84a and84b and its integral end portion I is mounted on a standard 81 by a pinor bolt 86 which extends through a bifurcated portion of the standard81. As shown particularly in Figure 13, the arm member I5 can be swungfrom a normal position E in alignment with the bottom of the furnace I0to a side position F when an ingot is to be removed or sawed ofi.

Referring particularly to Figures 13, 14, 15 and 16, I have shown a sawmechanism which like the arm member I5 and its associated mechanism ismounted within the enclosure 00. The saw mechanism has a rotating sawblade I0! provided with a shaft I08 splined thereto (see Figure 14). Theshaft I08 is journaled on a swing arm I I I and carries a sprocket wheelI09 which is secured on its lower, reduced, threaded end I08a by amounting nut IIO. A chain I I6 meshes with the sprocket I09 and isdriven by a sprocket I I5 that is splined or secured on an actuatingshaft H2. The shaft II2 also has a second sprocket wheel I I1 securedthereto and driven by a chain I I8 and a sprocket III! of a gearreduction unit I20. The shaft of an electric motor I2 I is coupled tothe unit I20. The shaft H2 is journaled at its lower end in a mountingH3 and at its upper end Illa is reduced, threaded, and journaled withinthe swing arm III. A nut and washer assembly II4 holds the swing arm I II pivotally in position on the reduced end I I2a of the drive shaft II2.

An opposite end of the arm I I I is actuated by a swing link pin I22which extends through a bifurcated end I24a of a piston rod I24 which isactuated by a fluid motor I25. Actuating fluid is introduced andexhausted from the motor I25 by connections I25a and I25b. The motor I25has an integral extension I26 that is secured within the bifurcatedportion of a standard I28 by a pin or bolt I21. As shown particularly inFigure 13, the arm III and its associated saw I01 is adapted to be movedfrom an inoperative position G to a sawing position H when the bottomWall 16 of the furnace or crucible has been lowered by the arm member I5and swung to outer position F of Figure 13. The fluid motors 84 and I25are of a double-acting type, so that they can be moved positively ineither direction. The motors 83 may be of either a singleor doubleactingtype.

To support the build-up ingot I when the bottom I6 of the furnace hasbeen removed, see Figures 14 and 15, I have provided a fluid motor I 04which has a piston rod I05 and a support head I05a that is adapted tomove through an opening I000. in a delivery chute I 00. Fluid issupplied to and exhausted from the motor I04 by connections I04a andI04b and it is preferably double-acting. As shown in Figure 14, themotor I04 supports the bottom of the ingot I, after its weight moves itout of the furnace I0 and into a sawing position. The length of ingotwhich is out can thus be governed by the vertical position of the headI05a of the motor I04. As shown in Figure 15, the major portion orlength I of the ingot is supported by the vertically movable head ortable I05a during the sawing-off operation. The remainder of the ingot Iis of relatively short length and thus of relatively slight weight andis free to move vertically-upwardly within the guiding walls of thecrucible or furnace I0. The table I05a is preferably lowered slightlyduring the operation to ease off the lower ingot portion I. Thus, nodifficulty is encountered from the standpoint of a binding of the sawduring the cutting-off operation.

After an ingot I has been sawed off, as shown particularly in Figures 15and 16, the head I05a can be lowered, as shown by the dot and dash linesof Figure 15, and the cut-off ingot I will fall into the delivery chuteI00 and move to the full line position shown, to the right of thisfigure.

The inclined chute I00 is mounted on a standard I03 at its upper end andon a standard IOI at its lower end. As shown particularly in Figure 16,it is provided with side walls I00b, an upper closure 90.

rolls Zia-fill),

haying primary taps T and prim 9 end well we and a a tment end wa l I.112 for guidin and po onin th cut=ofi in ot A s emental airloc ham eris p ov d d at the delivery end of the enclosure 90 and is defined by anenclosure 9|, see Figures 15 and 16. An opening 90a through a verticalWall of the enclosure 90 permits ingots to be delivered to the airlockchamber of the enclosure 9|. It will be noted that the inclined chuteHi0 also rests upon a lower portion of the wall $901) of the en- A door96 having a handle 96a is slidably mounted on the wall of the enclosure90 by flanges 97 and sealing-off gasket material 98 to normally closeoff the opening etc, This door .96 is raised when an ingot I is to bede- H ings, I have shown a pair of motor-generator sets 10a and 10b thatare connected in parallel for supplying I). C. current for weldingadjacent sticks, such as B and B" together. The set 10b also providesarcing current for the furnace Hi.

The motor generator set 10a on its positive side is connected through aline "Ha, switch 13a, and bearings 23 (see Figure 8') to the upper pairof its negative side is connected by a line lilac to the negative sidei229 of 'th other set lilb and through bearings 23 *2) to the lower pairof feed rollers din- 2 i h. positive side of the motor generator setconnected by a line 1 lb, switch 13c, and a l" cable lib to the arm "Hi,and time, tothe bottom "it. It will thus be app potential will besupplied. to the unitary electrode B'--B" and arcing current oi oppositepotential will be supplied to the metal (3 thrci h the furnace bottoml6. Thus an will be established between C and B of Figure 2.

When an upper electrode stick, such as B" is to be secured (as by ii-ashwe d' a) to a lower stick such as B, it is ied into an odwise abuttingrelationship with the lower stick (see Figure 3) by the pusher 4305, isaligned n such position by the idler guide rolls illa iib, current ofone potential is then supplied through the line Ha to the stick B" byclosing the switch "its. Current of opposite potential applied to theother stick B through line 12a. After the welding operation, the switchits is opened.

The pusher 49a keepsthe stick B" in welding abutment with the stick 3during the welding operation, although the latter being adwaneed slowlyinto the furnace is! hy the driven is rolls 2! 'a andilb. After thewelding operation, the pusher 49a may be raised and the welded stickswill then be fed as unitary electrode by the rolls 2 I 'a and 2 l "-b.

In Figure 1'? I have disclosed a uti three-phase alternating current fors pplyire; energy to a plurality of consumable electrodes. In thisdiagram P1, and P3 primaries for the various phases of an A. C.transformer, while S1, S2 and S3 are cor spcndi e secondaries there of.Switches S and 1 vid a1 phase transformers on daries Pie-S4, Pe -S andPi --56, respectively,

a e sh n The secon aries 5 and S6 a connected thr h switches r to the uper ol pa rs m a d Z for fi eti s a weldi g op rati n b tween ad c telect od stick Sw tch SW1 are ocat d one l ad o a h phase s c n ary totu n the c-pr d c r e for each electro e wh n d ir e other d of achphase S cond y i con c ed o the l w set of feed ro'ljls 2|d.- 2i"b.Although I have shown a plurality of furnaces or crucibles ill actuatedby the three-phase A. C. circuit, it will be apparent that a singlefurnace or crucible may be used and provided with a plurality of feedopenings for feeding a plurality of sticks, ii. a larger size of ingotis to be produced. As wn, the number of transformers used will dep. -dupon the number of phases of the A. 0. current source.

Although it has been customary to employ a direct current source ()1energy where a nonconsumable electrode is used and to connect itsnegative lead to the electrode to minimize its deterioration,alternating current has heen i'ouncl to be suitable where the electrodeis of a consumable type. As shown in Figure I prefer to connect thepositive lead of a direct current source to a consumable electrode toincrease its melting rate.

What I claim is:

i *1 apparatus of the character described for metal ingots in a furnacecrucible utiliza consumable electrode made up of preformed sticks ofair-sensitive metal, the c0rn-hination oi a carrier provided with aseries of stick-=- recei'ving compartments therein, sealing-offenclosure for said carrier, a second sealing-off enclosure positionedbeneath firstanentioned enclosure and on the furnace crucible over anopening therein, an opening through the top of said second enclosureinto said first enclosure, guide means positioned within said secondenclosure in alignment with the top opening therein and having portionsto guide sticks through the opening of and into the furnace crucible,means actuating said carrier to periodically and progressively aligneach of its compartments with the top opening said second enclosure, and

operably positioned within said first errclosu-re to advance a stickfrom an aligned compartment of said carrier through the top opening ofsaid second enclosure into engagement with said guide means.

2. In an apparatus as defined in claim 1 wherein, said last-mentionedmeans is a pusher operably positioned for movement along an alignedcompartment of said carrier and operably con.- nected to a'fluid motor.

3. In apparatus as defined inclaim 2 where.- in said guide means has apair of pass-defining, posi sly-driven feed. rolls; said pusher isadapted to he periodically actuated by said fluid r at a faster ratethan the rate of feed of d rolls to move a second stick from a reconcompartment of said carrier into endw e abutment with thefirst-mentioned stick that within the pass of said pair of feed rolls,and means positioned within said second enclosure to weld the abuttingsticks together into unitary electrode.

4. In apparatus of the character described for making metal ingots in afurnace crucible utilizing a consumable electrode made up of preformedsticks of air-"sensitive metal, the combination of a carrier providedwith a series of stickreceiving compartments therein, a sealing-citenclosure for said carrier, a second sealing-off enclosure positionedbeneath said first-mentioned enclosure and on the furnace crucible overan opening therein, an opening through the top of said second enclosureinto said first enclosure, means actuating said carrier to periodicallyand progressively align each of its compartments with the top opening ofsaid second enclosure, means operably positioned within said firstenclosure to advance a stick endwise from an aligned compartment of saidcarrier through the top opening thereof into said second enclosure,guide means operably positioned in said second enclosure to receivesuccessive sticks from pe riodically aligned compartments of saidcarrier and advance them into the furnace crucible, and electric weldingmeans operably associated with said guide means and positioned in saidsecond enclosure in alignment with the path of movement of the stickstherethrough and having portions connected to welding current ofopposite potential to weld abutting edges of a pair of sticks togetherinto a unitary electrode before they are introduced into the furnacecrucible.

5. In apparatus of the character described for making metal ingots in afurnace crucible utilizing a consumable electrode made up of preformedmetal sticks, the combination of a carrier provided with a series ofstick-receiving compartments therein, a sealing-oil enclosure for saidcarrier, a second sealing-oil enclosure positioned beneath saidfirst-mentioned enclosure and on the furnace crucible over an openingtherein, an opening through the top of said second enclosure into saidfirst enclosure, means actuating said carrier to periodically andprogressively align each of its compartments with the top opening ofsaid second enclosure, means operably positioned within said firstenclosure to advance a stick endwise from an aligned compartment of saidcarrier through the top opening thereof into said second enclosure,guide means operably positioned in said second enclosure to receivesuccessive sticks from periodically aligned compartments of said carrierand advance them into the furnace crucible, said guide means comprise anupper pair of rolls in operative engagement with one of the sticks to bewelded, and a lower pair of rolls in operative contact with the other ofthe sticks to be welded; a source of current of one potential adapted tobe connected to intermittently supply said upper pair of rolls, a sourceof current of opposite potential continuously connected to supply saidlower pair of rolls, means connecting the source of current of onepotential to the furnace crucible, and the current of opposite potentialconnected to said lower pair of rolls being supplied by its source tothe electrode provided by the welded sticks for effecting the arcmelting operation within the furnace crucible.

6. In an apparatus as defined in claim wherein, means is provided foractuating said lower pair of rolls to advance the welded electrode intothe furnace crucible, and said means for advancing a stick from analigned compartment of said carrier has means for reciprocating it toadvance a stick therein into abutment with a preceding stick that isbeing advanced by said lower pair of rolls and to Withdraw and advanceanother stick into abutment with the second stick.

7. In an arc melting furnace apparatus of the character described formaking ingots from preformed composite consumable electrode sticks of anair-sensitive metal, the combination of a rotatable carrier wheelprovided with a series of radially-positioned stick-receivingcompartments, an enclosure about said wheel, means rotatably mountingsaid wheel within said enclosure, a feed chute mounted on said enclosurefor feeding sticks into the compartments of said wheel as it is rotated,said feed chute having an airlock for normally excluding contaminatinggases from said enclosure, a pusher means operably mounted on saidenclosure above the path of movement of the compartments of said wheel,a feed opening through the bottom of said enclosure, means forperiodically moving said pusher means into and along each of thecompartments of said wheel to push a stick out through the opening inthe bottom of said enclosure, a. second enclosure about the bottom ofsaid first-mentioned enclosure and having a feed portion open to and inalignment with the feed opening in said first-mentioned enclosure,vertically spacedapart pairs of rolls operably mounted in said secondenclosure in an aligned-stick-feeding relationship with respect to eachother, said pusher means having a path of operative movement suflicientto push a stick from each compartment of said wheel into a pass formedby an upper pair of said rolls, a lower pair of said rolls having aspaced relationship with respect to said upper pair that is shorter thanthe length of a stick being fed, said second-mentioned enclosure beingmounted on the arc-melting furnace and having an opening through abottom thereof into the furnace, and means for actuating said lower pairof rolls to advance a stick through the opening in the bottom of saidsecond enclosure into the furnace to provide an electrode therefor.

8. In an apparatus as defined in claim 7 wherein, said upper pair ofrolls is positioned to guide a second stick into abutment with a stickwithin the pass of said lower pair of rolls, and means is provided forsupplying electric current of opposite potential to said upper and lowerfeed roll pairs to weld the abutting sticks together to form a unitaryelectrode for the furnace.

SCHUYLER A. HERRES.

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